Pressure relief valve system

ABSTRACT

Various methods and systems are provided for a pressure relief valve of a fuel system. In one example, a valve includes a first chamber in fluid communication with a first fuel line, a second chamber in fluid communication with a second fuel line and in fluid communication with a fuel storage tank, a piston separating the first chamber from the second chamber, and a needle coupled to the piston and controlling a flow passage between the second fuel line and the second chamber, where the piston and needle are sized such that a force applied on the piston by the first chamber parallel to an axis of movement of the piston maintains the needle in a closed position when the first fuel line flows fuel at a first pressure and the second fuel line flows fuel at a second pressure, the second pressure greater than the first pressure.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. Non-Provisional patentapplication Ser. No. 14/747,748 entitled “PRESSURE RELIEF VALVE SYSTEM”,and filed on Jun. 23, 2015. U.S. Non-Provisional application Ser. No.14/747,748 claims priority to U.S. Provisional Application No.62/049,776, entitled “PRESSURE RELIEF VALVE SYSTEM”, and filed Sep. 12,2014. The entire contents of each of the above-listed applications arehereby incorporated by reference for all purposes.

BACKGROUND Technical Field

Embodiments of the subject matter disclosed herein relate to a fuelsystem for an engine, for example.

Discussion of Art

High pressure fuel rails are typically equipped with a means of pressurerelief to release pressure from the fuel rail. For example, ifmaintenance is to be performed on the fuel rail or other fuel systemcomponents, the pressure from the fuel rail is relieved via a pressurerelief valve to prevent high pressure fuel spray from being directedonto the maintenance personnel. Some fuel rail pressure relief valvesare manually operated, such that the maintenance personnel manuallyopens the valve prior to beginning maintenance. However, if thepersonnel forgets to open the valve, high pressure fuel spray may beunexpectedly released during maintenance. Other fuel rail pressurerelief valves may be automatically opened at engine shutdown, via asolenoid valve under control of a controller, for example. Such valvesare costly and complicated to control. Further, if the engineexperiences an emergency shut-down, electrical energy used to open thevalve may not be available. Yet another type of valve may energize theinjectors in short pulses to bleed fuel pressure internally through theinjector; however, this type of valve also requires electrical energy.

BRIEF DESCRIPTION

In one embodiment, a valve comprises a first chamber in fluidcommunication with a first fuel line, a second chamber in fluidcommunication with a second fuel line and in fluid communication with afuel storage tank, a piston separating the first chamber from the secondchamber, and a needle coupled to the piston and controlling a flowpassage between the second fuel line and the second chamber, where thepiston and needle are sized such that a force applied on the piston bythe first chamber parallel to an axis of movement of the pistonmaintains the needle in a closed position when the first fuel line flowsfuel at a first pressure and the second fuel line flows fuel at a secondpressure, the second pressure greater than the first pressure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic diagram of a common fuel rail system accordingto an embodiment of the invention.

FIG. 2 shows a schematic of a pressure relief valve of a common fuelrail system in a closed position according to an embodiment of theinvention.

FIG. 3 shows a schematic of a pressure relief valve of a common fuelrail system in an open position according to an embodiment of theinvention.

FIG. 4 shows a schematic diagram of a common fuel rail system accordingto another embodiment of the invention.

DETAILED DESCRIPTION

The following description relates to embodiments of a pressure reliefsystem including a means of pressure relief. In one example, the meansof pressure relief is a pressure relief valve. The valve includes afirst chamber in fluid communication with a first fuel line, a secondchamber in fluid communication with a second fuel line and in fluidcommunication with a fuel storage tank, a piston separating the firstchamber from the second chamber, and a needle coupled to the piston andcontrolling a flow passage between the second fuel line and the secondchamber, where the piston and needle are sized such that a force appliedon the piston by the first chamber parallel to an axis of movement ofthe piston maintains the needle in a closed position when the first fuelline flows fuel at a first pressure and the second fuel line flows fuelat a second pressure, the second pressure greater than the firstpressure.

As one embodiment, the valve may be installed in a common fuel railsystem, such as the common fuel rail system shown in FIG. 1 or FIG. 4.The first fuel line is in fluid communication with a fluid conduitcoupled between a low pressure pump and a high pressure pump of thecommon fuel rail system. Additionally, the second fuel line is fluidlycoupled to a common fuel rail (e.g., common high pressure fuel rail) ofthe common fuel rail system. FIG. 2 shows the valve in the closedposition. When the force applied on the piston decreases below a forceapplied on the needle parallel to the axis of movement of the piston,the valve moves into an open position, as shown in FIG. 3. The valve mayopen during engine shutdown and/or when the pressure in the second fuelline increases above a threshold pressure, thereby allowing fluid in thesecond fuel line to drain to a fuel tank via a drain passage of thevalve. In this way, fluid pressure in the second fluid line may bereduced during engine shutdown or when fuel rail pressure increasesabove the threshold pressure.

The approach described herein may be employed in a variety of enginetypes, and a variety of engine-driven systems. Some of these systems maybe stationary, while others may be on semi-mobile or mobile platforms.Semi-mobile platforms may be relocated between operational periods, suchas mounted on flatbed trailers. Mobile platforms include self-propelledvehicles. Such vehicles can include on-road transportation vehicles, aswell as mining equipment, marine vessels, rail vehicles, and otheroff-highway vehicles (OHV). For clarity of illustration, a locomotive isprovided as an example of a mobile platform supporting a systemincorporating an embodiment of the invention.

As used herein, “high pressure” and “low pressure” are relative to oneanother, meaning the high pressure is a pressure higher than the lowpressure, and the low pressure is a pressure lower than the highpressure. As such, a high pressure portion of a fuel system may includefuel at a higher pressure than a low pressure portion of the fuelsystem.

Before further discussion of a pressure relief valve for a fuel system,a first example of a fuel system for an engine is disclosed. Forexample, FIG. 1 shows a block diagram of a common rail fuel system (CRS)100 for an engine of a vehicle, such as a rail vehicle. Liquid fuel issourced or stored in a fuel tank 102 (e.g., fuel storage tank). A lowpressure fuel pump 104 is in fluid communication with the fuel tank. Inthe embodiment shown in FIG. 1, the low pressure fuel pump is disposedinside of the fuel tank and can be immersed below the liquid fuel level.In alternative embodiments, the low-pressure fuel pump may be coupled tothe outside of the fuel tank and pump fuel through a suction device.Operation of the low pressure fuel pump is regulated by a controller106. In one embodiment, the low pressure fuel pump (e.g., low pressurepump) is a remote electric pump not driven by the engine. In someexamples, the low pressure fuel pump may be referred to as a primingpump. Additionally, when power to the low pressure fuel pump is turnedoff, the low pressure side of the fuel system (e.g., all fluid conduitsand components upstream of a high pressure fuel pump) does not holdfluid pressure and instead the pressure decreases below priming oroperating pressure. In another embodiment, the low pressure fuel pumpshown in FIG. 1 may be an engine driven transfer pump.

Liquid fuel is pumped by the low pressure fuel pump from the fuel tankto a high pressure fuel pump 108 through a low pressure conduit 110. Thelow pressure fuel pump is decoupled from the drive of the high pressurefuel pump such that the pumps may operate independently from one another(e.g., power to the low pressure fuel pump may be shut off while thehigh pressure fuel pump continues to operate). In an alternateembodiment, the low pressure fuel pump may be mechanically driven by thehigh pressure pump and thus the low pressure fuel pump may not operateindependently from the high pressure fuel pump A valve 112 is disposedin the low pressure conduit and regulates fuel flow through the lowpressure conduit. For example, the valve is an inlet metering valve(IMV). The IMV 112 is disposed upstream of the high pressure fuel pumpto adjust a flow rate of fuel that is provided to the high pressure fuelpump and further to a common fuel rail 114 for distribution to aplurality of fuel injectors 118 for fuel injection. For example, the IMVmay be a solenoid valve, opening and closing of which is regulated bythe controller. In other words, the controller commands the IMV to befully closed, fully open, or a position in between fully closed andfully opened in order to control fuel flow to the high pressure fuelpump to a commanded fuel flow rate. During operation of the vehicle, theIMV is adjusted to meter fuel based on operating conditions, and duringat least some conditions may be at least partially open. It is to beunderstood that the valve is merely one example of a control device formetering fuel and any suitable control element may be employed withoutdeparting from the scope of this disclosure. For example, a position orstate of the IMV may be electrically controlled by controlling an IMVelectrical current. As another example, a position or state of the IMVmay be mechanically controlled by controlling a servo motor that adjuststhe IMV. In yet another embodiment, the CRS may not include an IMV andfuel pressure may be instead controlled on the high pressure side of thesystem. The low pressure conduit may also include a fuel filter (notshown in FIG. 1).

The high pressure fuel pump increases fuel pressure from a lowerpressure to a higher pressure. The high-pressure fuel pump is fluidlycoupled with the common fuel rail. The high-pressure fuel pump deliversfuel to the common fuel rail through a high pressure conduit 116. Aplurality of fuel injectors 118 are in fluid communication with thecommon fuel rail. Each of the plurality of fuel injectors delivers fuelto one of a plurality of engine cylinders 120 in an engine 122. Fuel iscombusted in the plurality of engine cylinders to provide power to thevehicle through an alternator and traction motors, for example.Operation of the plurality of fuel injectors is regulated by thecontroller. In the embodiment of FIG. 1, the engine includes four fuelinjectors and four engine cylinders. In alternate embodiments, more orfewer fuel injectors and engine cylinders can be included in the engine.

Excess fuel in the fuel injectors returns to the fuel tank via a commonfuel return 140. As such, the common fuel return is coupled to the fueltank. In other embodiments, the CRS may not include a common fuelreturn.

Fuel pumped from the fuel tank to an inlet of the IMV by the lowpressure fuel pump may operate at what is referred to as a lower fuelpressure or engine fuel pressure. Correspondingly, components of the CRSwhich are upstream of the high pressure fuel pump operate in the lowerfuel pressure or engine fuel pressure region. On the other hand, thehigh pressure fuel pump may pump fuel from the lower fuel pressure to ahigher fuel pressure or rail fuel pressure. Correspondingly, componentsof the CRS which are downstream of the high pressure fuel pump are in ahigher-fuel pressure or rail fuel pressure region of the CRS.

A fuel pressure in the lower fuel pressure region is measured by a lowerpressure sensor 126 that is positioned in the low pressure conduit. Thelower pressure sensor sends a pressure signal to the controller. In analternative application, the lower pressure sensor is in fluidcommunication with an outlet of the low pressure fuel pump. A fueltemperature in the lower fuel pressure region is measured by atemperature sensor 128 that is positioned in the lower pressure conduit.The temperature sensor sends a temperature signal to the controller.Additionally, a pressure regulator 127 may be positioned between the lowpressure fuel pump and the lower pressure sensor and temperature sensorin the low pressure conduit. Said another way, the pressure regulator127 may be coupled to the low pressure conduit and may relieve pressurein the low pressure conduit by directing fuel to the fuel tank. Thepressure regulator may be a low pressure fuel regulator for maintaininga pressure in the lower pressure side of the fuel system (e.g., in thelow pressure conduit and low pressure fuel line) within a set range.This may help to maintain a stable low pressure input to a low pressureside of a pressure relief valve (e.g., pressure relief valve 150),discussed further below. In another embodiment, the pressure regulatormay be included in the low pressure pump.

A fuel pressure in the higher fuel pressure region is measured by ahigher pressure sensor 130 that is positioned in the high pressureconduit. The higher pressure sensor sends a pressure signal to thecontroller. The controller uses this pressure signal to determine a railpressure of fuel (e.g., FRP) in the common fuel rail. As such, the fuelrail pressure (FRP) is provided to the controller by the higher pressuresensor. In an alternative application, the higher pressure sensor is influid communication with an outlet of the high pressure fuel pump. Notethat in some applications various operating parameters may be generallydetermined or derived indirectly in addition to or as opposed to beingmeasured directly.

In addition to the sensors mentioned above, the controller receivesvarious signals from a plurality of engine sensors 134 coupled to theengine that may be used for assessment of fuel control health andassociated engine operation. For example, the controller receives sensorsignals and then, based on these signals, determines one or more ofair-fuel ratio, engine speed, engine load, engine temperature, ambienttemperature, fuel value, a number of cylinders actively combusting fuel,and the like. In the illustrated implementation, the controller is acomputing device, such as microcomputer that includes a processor unit136, non-transitory computer-readable storage medium device 138,input/output ports, memory, and a data bus. The computer-readablestorage medium included in the controller is programmable with computerreadable data representing instructions executable by the processor forperforming the control routines and methods described below as well asother variants that are not specifically listed.

The controller is operable to adjust various actuators in the CRS basedon different operating parameters received or derived from differentsignals received from the various sensors, to dynamically assess thehealth of the CRS and control operation of the engine based on theassessment. For example, in an embodiment, the controller is operable toadjust fuel injection to the engine. Specifically, the controller mayadjust fuel injection timing of one or more fuel injectors based on adetermined injector activation time.

The CRS includes a hydraulic pressure relief valve 150 coupled between ahigh pressure side and low pressure side of the CRS. The high pressureside of the CRS is downstream from the high pressure fuel pump and thelow pressure side of the CRS is upstream from the high pressure fuelpump. More specifically, the pressure relief valve is coupled at a firstend to the low pressure conduit 110 via a low pressure fuel line 154.Thus, the fuel in the low pressure fuel line is supplied from the lowpressure fuel pump. The pressure relief valve is coupled at a second end152 to the common fuel rail 114 (e.g., high pressure fuel rail). Asdiscussed above, the fuel in the common fuel rail is supplied from thehigh pressure fuel pump. In some examples, the pressure relief valve maybe coupled to the common fuel rail by a connecting high pressure fuelline. In this way, the pressure relief valve is coupled between the lowpressure conduit, between the low pressure and high pressure pump, andthe high pressure fuel rail, downstream of the high pressure pump. Thepressure relief valve is further coupled to a drain passage 156, thedrain passage coupled to the fuel tank. For example, the drain passagemay allow fuel to drain from the pressure relief valve and to the fueltank. As described further below, the pressure relief valve is a singlevalve that is controlled passively by fluid pressures in the common fuelrail system. More specifically, the pressure relief valve opens andcloses based on a fluid pressure balance between the high pressure andlow pressure side of the fuel system alone. As such, no additionalforces other than the low fuel pressure and the high fuel pressure(e.g., such as a spring force) act on the valve to open or close thevalve.

FIG. 4 shows a second example of a fuel system for an engine thatincludes two banks of cylinders and two high pressure fuel rails. Forexample, FIG. 4 shows a block diagram of a common rail fuel system (CRS)400 for an engine of a vehicle having two cylinder banks (e.g., such asa V-engine), such as a rail vehicle. The CRS of FIG. 4 may includesimilar components to those described above with reference to FIG. 1.Thus, similar components have been numbered similarly and will not bere-described below. Further, CRS 400 shown in FIG. 4 may includeadditional or alternative components to those shown in FIG. 4.

Liquid fuel is sourced or stored in a fuel tank 102 (e.g., fuel storagetank). A low pressure fuel pump 104 is in fluid communication with thefuel tank. In the embodiment shown in FIG. 4, the low pressure fuel pumpis disposed outside of the fuel tank and pumps fuel through a suctiondevice. Operation of the low pressure fuel pump is regulated by acontroller 106 and the controller may function as described above withreference to FIG. 1. As described above, when power to the low pressurefuel pump is turned off, the low pressure side of the fuel system (e.g.,all fluid conduits and components upstream of a high pressure fuel pump)does not hold fluid pressure and instead the pressure decreases belowpriming or operating pressure.

Liquid fuel is pumped by the low pressure fuel pump from the fuel tankto two high pressure fuel pumps through a low pressure conduit 110.Specifically, the low pressure fuel pump pumps fuel to a first highpressure fuel pump 402 coupled to a first high pressure fuel rail 406and a second high pressure fuel pump 404 coupled to a second highpressure fuel rail 408. The first and second high pressure fuel pumpsmay operate similarly to the high pressure fuel pump 108 described abovewith reference to FIG. 1. The low pressure conduit may include a fuelfilter 424. In FIG. 4, the fuel filter is shown downstream of the lowpressure fuel pump; however, in alternate embodiment, the fuel filtermay be disposed in an alternate location in the low pressure conduit.

The low pressure fuel pump is decoupled from the drives of the first andsecond high pressure fuel pumps such that the pumps may operateindependently from one another (e.g., power to the low pressure fuelpump may be shut off while the first and second high pressure fuel pumpscontinues to operate). In an alternate embodiment, the low pressure fuelpump may be mechanically driven by one or both of the high pressurepumps and thus the low pressure fuel pump may not operate independentlyfrom the high pressure fuel pumps. As shown in FIG. 4, a first inletmetering valve 420 is coupled upstream of the first high pressure fuelpump and a second inlet metering valve 422 is coupled upstream of thesecond high pressure fuel pump. Thus, the low pressure conduit couplesto a second low pressure conduit 418 extending between an inlet to thefirst inlet metering valve and an inlet to the second inlet meteringvalve. The first and second inlet metering valves are configured toadjust a flow rate of fuel that is provided to the first and second highpressure fuel pumps, respectively, and further to the first and secondhigh pressure fuel rails, respectively, for distribution to a pluralityof fuel injectors 118 for fuel injection.

In an alternate embodiment, a single inlet metering valve 112 may bedisposed in the low pressure conduit upstream of both the first andsecond high pressure fuel pumps to adjust a flow rate of fuel that isprovided to the first and second high pressure fuel pumps and further tothe first and second high pressure fuel rails for distribution to aplurality of fuel injectors 118 for fuel injection. In anotherembodiment, the CRS may not include an IMV and fuel pressure may beinstead controlled on the high pressure side of the system (e.g.,downstream from each of the first and second high pressure fuel pumps).

The high pressure fuel pumps increases fuel pressure from a lowerpressure to a higher pressure. The first high-pressure fuel pumpdelivers fuel to the first high pressure fuel rail through a highpressure conduit 410. A first set of fuel injectors 412 for a first bankof the engine are in fluid communication with the first high pressurefuel rail. Each of the first set of fuel injectors delivers fuel to oneof a plurality of engine cylinders of a first bank of the engine(similar to the engine of FIG. 1). Operation of the first set of fuelinjectors is regulated by the controller. In the embodiment of FIG. 4,the engine includes six fuel injectors and six engine cylinders on eachengine bank. In alternate embodiments, more or fewer fuel injectors andengine cylinders can be included in the engine.

Similarly, the second high-pressure fuel pump delivers fuel to thesecond high pressure fuel rail through a high pressure conduit 414. Asecond set of fuel injectors 416 for a second bank of the engine are influid communication with the second high pressure fuel rail. Each of thesecond set of fuel injectors delivers fuel to one of a plurality ofengine cylinders of a second bank of the engine. Operation of the secondset of fuel injectors is regulated by the controller.

Excess fuel in the fuel injectors returns to the fuel tank via a commonfuel return 140. As such, the common fuel return is coupled to the fueltank. In other embodiments, the CRS may not include a common fuelreturn.

The CRS includes a hydraulic pressure relief valve 150 coupled between ahigh pressure side and low pressure side of the CRS. The high pressureside of the CRS is downstream from the first and second high pressurefuel pumps and the low pressure side of the CRS is upstream from thefirst and second high pressure fuel pumps. More specifically, thepressure relief valve is coupled at a first end to a second low pressureconduit 418 extending between an inlet to the first inlet metering valveand an inlet to the second inlet metering valve via a low pressure fuelline 154. Thus, the fuel in the second low pressure fuel line issupplied from the low pressure fuel pump. The pressure relief valve iscoupled at a second end 152 to both the first high pressure fuel railand the second high pressure fuel rail. As discussed above, the fuel inthe first high pressure fuel rail is supplied from the first highpressure fuel pump and the fuel in the second high pressure fuel rail issupplied from the second high pressure fuel pump. In this way, thepressure relief valve is coupled between the low pressure conduit,between the low pressure and both the first and second high pressurepumps, and the first and second high pressure fuel rails, downstream ofthe first and second high pressure pumps. The pressure relief valve isfurther coupled to a drain passage 156, the drain passage coupled to thefuel tank. As described further below, the pressure relief valve is asingle valve that is controlled passively by fluid pressures in thecommon fuel rail system. More specifically, the pressure relief valveopens and closes based on a fluid pressure balance between the highpressure and low pressure side of the fuel system alone. As such, noadditional forces other than the low fuel pressure and the high fuelpressure (e.g., such as a spring force) act on the valve to open orclose the valve.

FIGS. 2-3 show schematics of the pressure relief valve in furtherdetail. Specifically, FIG. 2 shows a first schematic 200 of the pressurerelief valve 150 in a closed position blocking communication between thehigh pressure fuel rail and the fuel tank. FIG. 3 shows a secondschematic 300 of the pressure relief valve 150 in an open positioncoupling the high pressure fuel rail to the fuel tank via the drainpassage 156 (e.g., drain conduit).

The pressure relief valve includes a movable piston 202 positionedwithin a valve body 204 of the pressure relief valve. A needle 206 iscoupled to the piston. The pressure relief valve further includes afirst chamber 208 and a second chamber 210 defined by the interiorsurface of the valve body and the piston. The piston completelyseparates the first chamber from the second chamber so that there is nofluid communication between the first chamber and the second chamber. Inone example, the valve body is cylindrical and the piston has a circularcross-section fitting within the cylindrical valve body. For example,outer edges of the piston contact and slide against interior edges ofthe valve body. In alternate embodiments, the valve body and piston havea different shape (e.g., square or rectangular), but the piston stillcontacts all interior edges of the valve body in order to fluidlyseparate the first chamber from the second chamber.

The valve body includes a first opening 212 coupling the first chamberto the low pressure fuel line 154 (e.g., first fuel line). As such, thefirst opening fluidly couples the first chamber to a first fluid 214flowing through the low pressure fuel line. As described above, the lowpressure fuel line may be coupled to a low pressure conduit in thecommon rail system that is coupled between the low pressure and highpressure fuel pump (in the system of FIG. 1) or both high pressure pumps(in the system of FIG. 4). Thus, the first fluid may be fuel in thecommon rail system at a first pressure. The first pressure may bereferred to herein as a pressure in the low pressure side of the commonrail fuel system, P_(LP). Fluid may flow freely from the low pressurefuel line into the first chamber. The piston has a piston fluid surfacearea 216 (e.g., surface area) exposed to the first fluid in the firstchamber. More specifically, the piston fluid surface area has a firstfluid frontal area defined by the geometry of the piston, the firstfluid frontal area being a first fluid-exposed frontal area exposed tothe first fluid. For example, if the piston is cylindrical with acircular cross-section, the first fluid frontal area is the area of thecircular cross-section. The first fluid applies a first force 218,F_(LP) against the piston in a direction parallel to an axis of movementof the piston (e.g., axis 242 shown in FIGS. 2-3). F_(LP) may bedetermined by the following formula:F _(LP) =P _(LP) *A _(piston),where A_(piston) is the first frontal area of the piston (e.g., pistonsurface area exposed to fuel in first chamber). Thus, as the pressure inthe lower pressure side of the fuel system increases, the force appliedto the surface of the piston also increases.

The valve body also includes a second opening 220 coupling the secondchamber to a second fuel line (e.g., high pressure fuel line) 222. Inone example, the high pressure fuel line is directly coupled to one ormore high pressure fuel rails (e.g., common fuel rail 114 shown in FIG.1 or first and second high pressure fuel rails 406 and 408 shown in FIG.4), without any additional components between the high pressure fuelline and the fuel rail(s). In another example, the high pressure fuelline is the high pressure fuel rail such that the fuel rail is directlycoupled to the second chamber via the second opening. The second openingfluidly couples the second chamber to a second fluid 224 flowing throughthe high pressure fuel line and the common fuel rail (or through each ofthe first and second high pressure fuel rails). The second fluid may bethe fuel in the common rail system at a second pressure. The secondpressure may be referred to herein as a pressure in the high pressureside of the common rail fuel system, P_(HP).

For example, if the common rail system includes two high pressure fuelpumps and fuel rails, such as common rail system shown in FIG. 4, thesecond fluid may be fuel flowing through a high pressure fuel linecoupled to both the first and second high pressure fuel lines. As such,the second pressure may be based on the pressure in both of the firstand second high pressure fuel rails.

The valve body further includes a third opening 226 coupling the secondchamber to the drain passage 156. The drain passage has a first endfluidly coupled to a side of the valve body. In other embodiments, thethird opening may be positioned at a different location of the valvebody, but still fluidly coupled to the second chamber (e.g., a same sideas the second opening). Additionally, as shown in FIG. 1 and FIG. 4, thedrain passage is coupled at a second end to the fuel tank. The drainpassage includes a fuel sensor 228 that sends a signal to the controllerwhen fuel is flowing through the drain passage and to the fuel tank.Thus, the fuel sensor may indicate when fuel is being drained from thehigh pressure valve and to the fuel tank.

The pressure relief valve also includes a dampening spring 230 thatdampens the movement of the piston within the valve body. For example,the spring may keep the piston from moving too quickly between the openand closed positions as the first pressure and the second pressurechange. Thus, the spring provides dampening only and does not open andclose the valve. Additionally, the spring may maintain the valve in theopen position, after it has already been opened, during an engineshutdown mode.

The needle includes a stem. The stem has a first end 231 coupled to atapered tip 232 of the needle. An outer circumference of the first endof the stem is adapted to contact a seat 234 of the valve body (e.g.,may also be referred to as a seat of the high pressure fuel line) toblock flow of fuel from the high pressure fuel line into the secondchamber when the needle is in the closed position, as shown in FIG. 2.The seat may define the second opening. The needle has a needle fluidsurface 238 (e.g., needle surface area) exposed to the second fluidsource. More specifically, the needle fluid surface has a second fluidfrontal area defined by the geometry of the needle, the second fluidfrontal area being a second fluid-exposed frontal area exposed to thesecond fluid (e.g., surface area of needle exposed to fuel in fuelpassage). The second fluid frontal area is based on a fluid-exposeddiameter of the needle tip and a fluid-exposed length of the needle tip.The second fluid applies a second force 240, F_(HP), against the pistonin a direction parallel to the axis of movement of the piston (e.g.,axis 242). F_(HP) may be determined by the following formula:F _(HP) =P _(HP) *A _(needle),where A_(needle) is the first frontal area of the needle (e.g., needlesurface area exposed to fuel). Thus, as the pressure in the higherpressure side of the fuel system increases, the force applied to thesurface of the needle also increases.

The piston is movable vertically within the valve body with respect to avertical axis 236. The needle is coupled to a bottom side of the piston,opposite the piston fluid surface exposed to the first fluid. Since theneedle is directly coupled to the piston, without any additionalcomponents between the piston and the needle, the needle movesvertically within the valve body with vertical movement of the piston.

When the pressure relief valve is in the closed position, as shown inFIG. 2, the needle fluid surface covers the second fluid opening suchthat there is no fluidic communication between the second fluid openingand the drain passage. In the closed position, the needle tip is incontact with the seat and no fluid flows from the high pressure fuelline (and the common fuel rail) and into the second chamber. Saidanother way, the needle tip blocks fluid from entering the secondchamber and flowing through the drain passage. As a result, the fluidpressure in the high pressure passage and the fuel rail may remain at aset pressure and may not be reduced.

When in the open position, as shown in FIG. 3, the needle fluid surfaceis positioned away from the second fluid opening such that there isfluidic communication between the high pressure fuel line (and thesecond opening) and the drain passage. As a result, fluid from the highpressure fuel line and fuel rail flows into the second chamber, throughthe third opening, and through the drain passage to the fuel tank,thereby resulting in a decrease in the second pressure (P_(HP)).

The position of the piston and needle within the valve body, and thusthe open and closed position of the pressure relief valve, is based onthe fluid forces (e.g., F_(LP) and F_(HP)) on the piston and needle. Asdescribed above, the fluid forces are directly proportional to therespective fluid pressure and frontal area. When F_(LP)>F_(HP), thepressure relief valve is closed, as shown in FIG. 2. F_(LP) may begreater than F_(HP) during engine priming, engine cranking and enginerunning (e.g., engine operation) when the rail pressure (e.g., P_(HP))is below a threshold pressure. The threshold pressure may be an upperthreshold at which continued operation may result in degradation of oneor more system components. At engine start-up, P_(HP) and P_(LP) may besubstantially zero. During engine priming prior to engine cranking, thehigh pressure pump is deactivated and the low pressure pump is operatedto supply fuel at a first pressure (greater than zero) to the pressurerelief valve. As P_(LP) increases to the first pressure while P_(HP)remains at substantially zero, F_(LP) is greater than F_(HP) and thepressure relief valve moves into the closed position. During enginecranking, the low pressure pump is operated to supply fuel at the firstpressure (e.g., in one example, approximately 5-7 bar) and the highpressure pump is activated to supply fuel at a second pressure (e.g.,approximately 700-1000 bar) to the pressure relief valve, the secondpressure higher than the first pressure. However, since the piston fluidfrontal area is proportionally larger than the needle frontal area, asdescribed further below, F_(LP) may remain greater than F_(HP), therebymaintaining the pressure relief valve in the closed position. Duringengine running (e.g., engine operation), the low pressure pump isoperated to supply fuel at the first pressure and the high pressure pumpis operated to supply fuel at a third pressure, the third pressurehigher than the first pressure and the second pressure. In one example,the third pressure is approximately 2200-2750 bar.

Conversely, when F_(HP)>F_(LP) the pressure relief valve is open, asshown in FIG. 3. F_(HP) may be greater than F_(LP) during engine runningwhen the rail pressure (e.g., P_(HP)) is greater than the thresholdpressure and/or upon engine shutdown when power to the low pressure pumpis turned off (e.g., during engine stop events). For example, followingengine shutdown, the low pressure pump is deactivated (e.g., turned off)before the high pressure pump is deactivated. As a result, fuel from thefuel rail is supplied to the pressure relief valve while fuel from thelow pressure fuel line (between the low pressure and high pressurepumps) quickly decreases to approximately zero. As a result, F_(HP)increase above F_(LP) and causes the pressure relief valve to open. Whenboth P_(HP) and P_(PL) reach approximately zero during engine shutdown,the spring of the pressure relief valve may hold the valve in the openposition. This may allow a maintenance personnel to safely work on thefuel rail system while the entire system is at a lower pressure (e.g.,approximately zero bar).

As shown in FIGS. 2-3, the piston fluid frontal area is larger than theneedle fluid frontal area. Since pressures in the high pressure side ofthe CRS may be approximately 100 times higher than the low pressure sideof the CRS, the piston fluid frontal area must be larger than the needlefrontal area. In some examples, the pressures in the high pressure sideof the CRS may be more than 100 times higher than the low pressure sideof the CRS. As a result, a smaller pressure on the low pressure side ofthe CRS (than on the high pressure side of the CRS) may maintain thepressure relief valve in the closed position. A geometry (e.g., size andshape) of the piston and the needle may be selected based on a pressurebalance equation relating the fluid force applied to the piston, F_(LP)and the fluid force applied to the needle, F_(HP). A pressure balanceequation for relating these two fluid forces is shown below:P _(LP) *A _(piston) +M*g=1.5*(P _(HP) *A _(needle))+S*L,where P_(LP) is the pressure of fluid in the low pressure side of theCRS (e.g., fluid pressure between the low pressure pump and the highpressure pump), A_(piston) is the piston frontal area, M*g is the weightof the piston (M is the mass of the piston, g is the gravitationalacceleration), 1.5 is safety factor (in other examples, may be adifferent number), P_(HP) is the pressure of fluid in the high pressureside of the CRS (e.g., fluid pressure downstream of the high pressurepump in the common fuel rail), A_(needle) is the needle frontal area, Sis the spring stiffness, and L is deflection of the spring from its freestate. The safety factor may be chosen based on a desired tolerance ofthe system. In an alternate embodiment where the valve is mounted upsidedown (e.g., in a reverse direction than shown in the figures), theweight of the piston may act to keep the valve in an open position whenthe engine is off and a spring may not be included in the valve system.

Variables M, g, S, and L are all known variables of the pressure reliefvalve. P_(LP) and P_(HP) may be measured or standard values underdifferent operating conditions. In one example, P_(HP) may be selectedto be the highest acceptable pressure below the threshold pressure.Additionally, A_(piston) may be limited based on the engine size andthus the size of the pressure relief valve. Thus, in one example,A_(piston) may be optimized based on engine size and then the pressurebalance equation may be used to determine the needle size. The needlesize and piston size may be adjusted based on a producible needle size(e.g., may be chosen from a set of pre-made or pre-sized needles). Inthis way, the diameters and/or sizes of the needle and piston may beselected based on the other variables described above in the pressurebalance equation.

As described above, the piston frontal area (e.g., cross-sectional area)is larger than the needle frontal area (e.g., cross-sectional area) duethe pressure of the fluid in the low pressure side of the CRS being lessthan the pressure of the fluid in the high pressure side of the CRS. Forexample, a ratio of the fluid is the low pressure side to the fluid inthe high pressure side of the CRS may be in a range of 1:100 to 1:600.Additionally, a radius of a cross-sectional area of a first end of thestem is smaller than a radius of a face of the piston.

The pressure relief valve described above may operate based on apressure balance between a high pressure side and low pressure side of acommon fuel rail system (e.g., the high pressure side downstream fromone or more high pressure pumps and the low pressure side upstream fromthe one or more high pressure pumps and downstream from a low pressurepump). The pressure relief valve may open based on the balancingpressure under two separate engine operating conditions with differentfluid pressure values. In one example, the pressure relief valve mayopen under a pressure-regulating mode when the fuel rail pressure (e.g.,fluid pressure on the high pressure side of the CRS) increases above athreshold pressure. As a result of opening the valve, pressure in thefuel rail may be reduced; thereby reducing damage to components of theCRS due to operating at the higher pressure. In the pressure-regulatingmode, the pressure relief valve opens in response to an increase in thefuel rail pressure above an upper threshold pressure, while the engineis operating and not in a shutdown mode. For example, the upperthreshold pressure may be an unusually high pressure excursion of thehigh pressure fuel rail system. In another example, the pressure reliefvalve may open during an engine shutdown mode, thereby reducing thepressure in the high pressure side of the CRS. Then, during enginemaintenance, maintenance personnel may safely work on the CRS withoutbeing subjected to a high pressure fuel spray. Thus, the pressure reliefvalve may be simply operated during two different pressure conditionsduring two different engine operating modes (e.g., one where the engineis operating and one where the engine is shut down). Further, thepressure relief valve may be sized (e.g., the A_(piston) and A_(needle))such that the valve opens under the necessary pressure conditions inboth the pressure-regulating mode and the engine shutdown mode. Inanother embodiment, the pressure regulating valve may be sized to openunder the necessary pressure conditions during just one of thepressure-regulating and engine shutdown modes.

As one embodiment, a hydraulic pressure relief valve may comprise amovable piston positioned within a valve body, the piston having apiston fluid surface exposed to a first fluid source, a needle coupledto the piston, the needle having a needle fluid surface exposed to asecond fluid source, and a drain passage fluidly coupled to a side ofthe valve body. The hydraulic pressure relief may further comprise afirst opening positioned in the valve body and fluidly coupled to thefirst fluid source and a second fluid opening positioned in the valvebody and fluidly coupled to the second fluid source. The valve ismovable between an open position and a closed position and when thevalve is in the closed position, the needle fluid surface covers thesecond fluid opening such that there is no fluidic communication betweenthe second fluid opening and the drain passage. Alternatively, when thevalve is in the open position, the needle fluid surface is positionedaway from the second fluid opening such that there is fluidiccommunication between the second fluid opening and the drain passage.The piston has a first fluid frontal area and the needle has a secondfluid frontal area, the first fluid frontal area larger than the secondfluid frontal area.

As another embodiment, a common rail system comprises a high pressurefuel rail coupled to a high pressure fuel pump, a low pressure fuel linecoupled between a low pressure fuel pump and the high pressure fuelpump, and a hydraulic valve coupled between the low pressure line andthe high pressure fuel rail, the hydraulic valve including a piston witha piston frontal area exposed to low pressure fluid in the low pressurefuel line and a needle coupled to the piston, the needle having a needlefrontal area exposed to high pressure fluid in the high pressure fuelrail. Further, the common rail system may include a second high pressurefuel rail coupled to a second high pressure fuel pump, the low pressurefuel line also coupled between the low pressure fuel pump and the secondhigh pressure fuel pump. The hydraulic valve may also be coupled betweenthe low pressure line and the second high pressure fuel rail. The needlefrontal area may then be exposed to high pressure fluid in a linecoupled to both the first and second high pressure fuel rails.

As yet another embodiment, a method comprises during a first conditionwhen a first fluid force applied to a first fluid-exposed surface of amovable piston of a hydraulic pressure relief valve is less than asecond fluid force applied to a second fluid-exposed surface of a needlecoupled to the piston, moving the hydraulic pressure relief valvecoupled between a first fluid and a second fluid into an open positionwhere the second fluid flows from a second side of the valve to a drainpassage coupled to the valve. The method further comprises during asecond condition when the first fluid force is greater than the secondfluid force, moving the hydraulic pressure relief valve into a closedposition where the there is no fluid communication between the secondfluid and the drain passage. In one example, the first conditionincludes when a pressure of the second fluid increases above a thresholdvalue and/or when a pump coupled to the first fluid shuts off during anengine shutdown.

In another embodiment, a valve comprises a valve body defining a firstchamber and a second chamber. The first chamber is configured to becoupled in fluid communication with a first fuel line. The secondchamber is configured to be coupled in fluid communication with a secondfuel line and in fluid communication with a fuel storage tank. The valvefurther comprises a piston separating the first chamber from the secondchamber, and a needle coupled to the piston. The needle is configured tocontrol a flow passage between the second fuel line and the secondchamber. The piston and needle are sized such that a force applied onthe piston by the first chamber parallel to an axis of movement of thepiston maintains the needle in a closed position when fuel in (orotherwise associated with) the first chamber is at a first pressure(e.g., when the first fuel line flows fuel at the first pressure) andfuel in (or otherwise associated with) the second chamber is at a secondpressure (e.g., when the second fuel line flows fuel at the secondpressure), the second pressure greater than the first pressure.

As still another embodiment, a valve comprises a first chamberconfigured for fluid communication with a first fuel line; a secondchamber configured for fluid communication with a second fuel line andfor fluid communication with a fuel storage tank; a piston separatingthe first chamber from the second chamber; and a needle coupled to thepiston and configured to control a flow passage between the second fuelline and the second chamber, where the piston and needle are sized suchthat a force applied on the piston by the first chamber parallel to anaxis of movement of the piston maintains the needle in a closed positionwhen the first fuel line flows fuel at a first pressure and the secondfuel line flows fuel at a second pressure, the second pressure greaterthan the first pressure.

As used herein, an element or step recited in the singular and proceededwith the word “a” or “an” should be understood as not excluding pluralof said elements or steps, unless such exclusion is explicitly stated.Furthermore, references to “one embodiment” of the invention do notexclude the existence of additional embodiments that also incorporatethe recited features. Moreover, unless explicitly stated to thecontrary, embodiments “comprising,” “including,” or “having” an elementor a plurality of elements having a particular property may includeadditional such elements not having that property. The terms “including”and “in which” are used as the plain-language equivalents of therespective terms “comprising” and “wherein.” Moreover, the terms“first,” “second,” and “third,” etc. are used merely as labels, and arenot intended to impose numerical requirements or a particular positionalorder on their objects.

This written description uses examples to disclose the invention,including the best mode, and also to enable a person of ordinary skillin the relevant art to practice the invention, including making andusing any devices or systems and performing any incorporated methods.The patentable scope of the invention is defined by the claims, and mayinclude other examples that occur to those of ordinary skill in the art.Such other examples are intended to be within the scope of the claims ifthey have structural elements that do not differ from the literallanguage of the claims, or if they include equivalent structuralelements with insubstantial differences from the literal languages ofthe claims.

The invention claimed is:
 1. A valve, comprising: a first chamberconfigured for fluid communication with a first fuel line, the firstfuel line in fluid communication with a fuel storage tank and configuredto flow fuel via a first opening in the first chamber; a second chamberconfigured for fluid communication with a second fuel line configured toflow fuel via a second opening in the second chamber and for fluidcommunication with the fuel storage tank via a third opening in thesecond chamber; a piston separating the first chamber from the secondchamber; and a needle including a first end coupled directly to thepiston and a second end including a tapered tip adapted to interfacewith the second opening, the needle extending through an entirety of thesecond chamber from the first end to the second end, the needleconfigured to control a flow passage between the second fuel line andthe second chamber, where the piston and the needle are sized such thata force applied on the piston by the first chamber parallel to an axisof movement of the piston maintains the needle in a closed position whenthe first fuel line flows fuel at a first pressure and the second fuelline flows fuel at a second pressure, the second pressure greater thanthe first pressure.
 2. The valve of claim 1, wherein when the needle isin the closed position, fuel in the second fuel line is blocked from thesecond chamber, and wherein when the needle is in an open position, fuelin the second fuel line passes through the flow passage and the secondchamber and out to the fuel storage tank.
 3. A system comprising thevalve of claim 2, a low pressure fuel pump, and a high pressure fuelpump, wherein fuel in the first fuel line is supplied from the lowpressure fuel pump and fuel in the second fuel line is supplied from thehigh pressure fuel pump via a fuel rail, the second fuel linefluidically coupled to the fuel rail.
 4. The valve of claim 2, wherein asurface area of the piston exposed to fuel in the first line and asurface area of the needle exposed to fuel in the second line are eachsized such that when fuel in the first fuel line drops below a lowpressure threshold, lower than the first pressure, the needle is movedinto the open position.
 5. The valve of claim 4, further comprising aspring in the second chamber and coupled to the piston, the springconfigured to maintain the needle in the open position if the fuel inthe first fuel line is below the low pressure threshold but not open andclose the valve.
 6. The valve of claim 2, wherein a surface area of thepiston exposed to fuel in the first line and a surface area of theneedle exposed to fuel in the second line are each sized such that whenfuel in the second fuel line exceeds a high pressure threshold, higherthan the second pressure, the needle moves into the open position. 7.The valve of claim 1, wherein the needle comprises a stem having a firstend coupled to the tapered tip, an outer circumference of the first endof the stem configured to contact a seat of the second opening to theflow passage to block flow of fuel from the second fuel line into thesecond chamber when the needle is in the closed position.
 8. The valveof claim 7, wherein an area of a face of the piston is greater than across-sectional area of the first end of the stem.
 9. The valve of claim7, wherein a radius of a cross-sectional area of the first end of thestem is smaller than a radius of a face of the piston.
 10. The valve ofclaim 1, wherein a ratio of the first pressure to the second pressure isin a range of 1:100 to 1:600.
 11. A system, comprising: an engine; afuel rail to supply fuel to a plurality of fuel injectors of the engine;a high pressure fuel pump to supply fuel to the fuel rail; a lowpressure fuel pump to supply fuel from a fuel storage tank to the highpressure fuel pump; and a pressure relief valve having a first chamberand a second chamber and fluidically coupled to the low pressure fuelpump at the first chamber and to the fuel rail and the fuel storage tankat the second chamber, the pressure relief valve including a pistoncoupled directly to a needle, the piston dividing the first chamber fromthe second chamber, the needle controlling a flow passage between thesecond chamber and the fuel rail, the pressure relief valve configuredto: be in a closed position during engine priming, engine cranking, andengine operation via the fluidic coupling between the low pressure pumpand the first chamber, thereby to maintain pressure in the fuel rail,automatically open upon engine shutdown via the fluidic coupling betweenthe fuel rail and the second chamber, thereby releasing a pressure inthe fuel rail, wherein the pressure relief valve is configured to be inthe closed position during engine operation when the pressure in thefuel rail is less than an upper threshold pressure and to automaticallyopen during engine operation when the pressure in the fuel railincreases above the upper threshold pressure; and wherein, duringpriming prior to engine cranking, the high pressure fuel pump isdeactivated and the low pressure fuel pump is operated to supply fuel ata first pressure to the pressure relief valve, the fuel at the firstpressure applying a force to close the pressure relief valve, whereinduring engine cranking, the low pressure fuel pump is operated to supplyfuel at the first pressure and the high pressure fuel pump is activatedto supply fuel at a second pressure to the pressure relief valve,wherein during engine operation, the low pressure fuel pump is operatedto supply fuel at the first pressure and the high pressure fuel pump isoperated to supply fuel at a third pressure, the second pressure and thethird pressure each higher than the first pressure and wherein the fuelsupplied at the first pressure is supplied at a pressure in a range of5-7 bar, the fuel supplied at the second pressure is supplied at apressure in a range of 700-1000 bar, and the fuel supplied at the thirdpressure is supplied at a pressure in a range of 2200-2750 bar.
 12. Thesystem of claim 11, wherein the low pressure fuel pump is operativelycoupled to be driven by the engine through a mechanical drive andincludes a pressure regulator to maintain a constant pressure at thefirst chamber of the pressure relief valve.
 13. The system of claim 11,wherein the high pressure fuel pump is operatively coupled to be drivenby the engine, and wherein the low pressure fuel pump is operativelycoupled to be driven by a motor, independent of the engine and whereinthe needle has a smaller diameter than the piston and the needle extendsthrough the second chamber to where the second chamber interfaces withthe fuel rail.
 14. The system of claim 11, wherein: a surface area ofthe piston exposed to fuel in the first chamber and a surface area ofthe needle exposed to fuel in the flow passage are each sized such thatthe force applied by the fuel at the first pressure on the pistonmaintains the needle in a first position where the flow passage isblocked, to maintain the pressure relief valve in the closed position,even when the fuel at the second pressure or the third pressure issupplied to the pressure relief valve.
 15. The system of claim 14,wherein following engine shutdown, the low pressure fuel pump isdeactivated and the high pressure fuel pump is deactivated and fuel fromthe fuel rail is supplied to the pressure relief valve while fuel at thefirst pressure is not supplied to the pressure relief valve, thereby tocause a force applied by the fuel from the fuel rail on the needle tomove the needle to a second position where fuel from the fuel rail isrouted through the second chamber and to the fuel storage tank.
 16. Asystem, comprising: an engine; a fuel rail to supply fuel to a pluralityof fuel injectors of the engine; a high pressure fuel pump to supplyfuel to the fuel rail; a low pressure fuel pump to supply fuel from afuel storage tank to the high pressure fuel pump; and a pressure reliefvalve positioned at the fuel rail and comprising: a first chamberfluidically coupled to the low pressure fuel pump via a first openingcoupling the first chamber to a low pressure fuel line, the low pressurefuel line in fluid communication with the fuel storage tank, where thelow pressure fuel line is adapted to receive fuel from the low pressurefuel pump; a second chamber fluidically coupled to the fuel rail via asecond opening in the second chamber and the fuel storage tank via athird opening in the second chamber; a piston separating the firstchamber from the second chamber; and a needle including a first enddirectly coupled to the piston and a second end including a tapered tip,the needle configured to control a flow passage between the secondchamber and the fuel rail via interaction of the tapered tip with thesecond opening, where the piston and the needle are sized such that aforce applied on the piston by the first chamber maintains the needle ina closed position when the low pressure fuel pump supplies fuel to thefirst chamber at a first pressure, even when the high pressure fuel pumpsupplies fuel to the fuel rail and pressure relief valve at a secondpressure that is greater than the first pressure.
 17. The system ofclaim 16, wherein the piston and the needle are further sized such thatthe needle is moved from the closed position to an open position, wherefuel flows from the fuel rail, through the second chamber, and to thefuel storage tank, during conditions where a force applied by fuel inthe flow passage on the needle is greater than the force applied by thefirst chamber on the piston, the conditions including one or more ofdeactivation of the low pressure fuel pump or fuel in the flow passageexceeding a high pressure threshold, greater than the second pressure.18. The system of claim 17, further comprising a sensor positioned inthe flow passage to detect if the pressure relief valve is open based ona flow rate of fuel in the flow passage.